unitas repair manual repair manual issue 4 jun 2014(0).pdfthe purpose of the unitas repair manual...

Unitas Repair Manual

Issue 4: June 2014

U n i t a s R e p a i r M a n u a l Page 1

Table of Contents

Page

Introduction 2

Definitions 3

1. Cleanliness 4

2. Pressure Vessel (Tank Shell) 5

3. Heating and Cooling 6

4. Insulation and Cladding 8

5. Frame 9

6. Paintwork 11

7. Walkway and ladder Assembly 12

8. Manway Assembly 13

9. Safety Release Valve 14

10. Top Valve 15

11. Bottom Valve 16

12. Appendages 18

13. Testing 19

Appendix A: Cleanliness Certificate 20

Appendix B: Corner Post Repairs 21

Appendix C: Cladding 23

Appendix D: Manlid 24

Appendix E: Safety Release Valve 25

Appendix F: Internal Inspection Report 26

Appendix G: ISO Dimensions & Tolerances 27

Appendix H: UNITAS Decals Specification 28


INTRODUCTION

The purpose of the Unitas Repair Manual (“Manual”) is to establish a uniform tank condition after repair

throughout Unitas’ global network of depots and maintaining safe tank container operation.

The Manual should be used by both depots (for repair criteria) and Lessees for following the required

maintenance and handling procedures. The standards described in this Manual apply to Lessees during

On-hire and Depots at Offhire.

It is the complete responsibility of the Lessee to ensure the tank container (“tank”) complies with all

conventions, laws and regulations or material requirements specific to the cargo, to the method of

carriage or to the route over which the tank is transported.

Lessee should comply with the requirements of any Customs Conventions on Containers including (but

not limited to) temporary admission. The tanks have been registered under the Approved Continuous

Examination Program (ACEP) of CSC and marked with ACEP decals. Lessee shall maintain the Containers in

full compliance with all the standards and regulations of CSC.

Any person going inside the tank vessel should be in compliance with all the prerequisites required or

recommended by the health and safety authorities having jurisdiction over both the location of the tank

and the tank itself.


DEFINITIONS

Acceptable and NOT Acceptable Condition

The condition guide which follows lists the component parts of a tank and describes what is acceptable

and what is not acceptable according to the standards laid out below.

NOT Acceptable Condition

Any damage or deterioration to a tank due to but not limited to Lessee failing to operate it according to

the below requirements shall not be deemed normal wear and tear. Damage which affects the safety,

structural integrity, cargo carrying capability, the ISO dimensions of the tank container, or where repairs

are improper or not in compliance with the applicable regulations.

THESE TYPES OF DAMAGES ARE THE LESSEE’S RESPONSIBILITY

Acceptable Condition

Acceptable condition or fair wear and tear which does not affect any of the above conditions.

ACCEPTABLE CONDITION IS THE LESSOR’S RESPONSIBILITY

NOTES:

• If any clarification is required as to acceptability or suitability of equipment then UNITAS should be

contacted.

• Where any component has to be replaced, the component should be “as built with”. If not available

then the component should be of a better quality than what it replaces.

• Some tank containers may be fitted with equipment which does not conform to the make and

specification stated in the text. Where there is doubt as to the suitability of this equipment please

consult UNITAS.

Fair Wear and Tear

‘Fair Wear and Tear’ is defined as deterioration of the tank or any of its component parts whilst being

properly maintained and used for its intended purpose. Any deterioration resulting from improper use,

improper maintenance or lack of maintenance is NOT ‘Fair Wear and Tear’.


1. CLEANLINESS

1.1. Exterior and Markings

NOT Acceptable Condition:

Previous cargo, contamination or odour

Oil, grease deposits

Road dirt reducing legibility of tank markings

Hazard warning labels or cargo labels

Operator logos

Non-standard labels or misleading marks

Remnants of labels

Insecure label holders

Glue residue

NOTE:

• The valve and manlid spillage trays must be clean and free of cargo spillage. Check any areas of

overspill for damage to paint and cladding and inspect drain tubes for blockages and check for

possible corrosion inside the spill box after removal of product stains.

1.3 Interior


Previous cargo, contamination or odour

Discolouration or transferable stain which can be removed by the manual application of a plastic abrasive

pad and/or solvent.

Corrosion, corrosion pitting, scratches or gouges

Missing, expired or Improper Cleanliness Certificate

Acceptable Condition:

Abrasion or scratches to finer than 120 grit polish equivalent

Only with zero pitting

NOTES:

• When the tank is received into the depot for Off-Hire, the depot must be in possession of a valid

Cleanliness certificate stating the proper shipping name and U.N. number of the last cargo carried in

the tank. No brand names. See Appendix A.

• The Cleanliness Certificate is valid for 7 days and must have the date of inspection later than the last

cargo or any internal work or internal cleaning.

• For man entry it is the responsibility of the depot supervisor to ensure that the tank is safe to enter.

This may require an inspection for gas contamination or low oxygen. (Gas Free Certificate)

• Tank containers are to be accepted into the depot for off-hire only when accompanied by a

Cleanliness Certificate. Tank containers without valid documentation must be considered unsafe and

should not be inspected. A Cleanliness Certificate issued by an independent party is required for all

tanks delivered off-hire.


2. PRESSURE VESSEL (Tank Shell)


Leaks

Cuts, cracks

Defects to welds or parent materials

Gouges, scratches and badly executed grinding, deeper than 0.1mm (0.004inch)

Excessive grinding or other metal depletion which reduces the shell thickness to less than the minimum

Grinding coarser than 120grit and excessive grinding scars/ uneven pattern.

Corrosion or corrosion pitting of any kind

Shell thickness below the required minimum or creates contamination traps.

Stress corrosion

Improper repairs or non-standard fittings

Sharp indentations, creases or dents causing the elastic limit of the material to be exceeded resulting in

permanent deformation

Dents greater than 6mm (0.25inch) to the top third of the tank shell

Dents greater than 10mm (0.4inch) to the bottom two thirds of the tank shell

Shell movement under overpressure / vacuum

Discolouration caused by cargo attack or overheating of the steel (internal/external)

Pitting and Porosity: Any pitting noted must result in a thorough investigation. An IIR (see Appendix F)

should be completed mapping the type of defect, area affected and location. The investigation must

ensure that cavity pitting is not present and that pitting is not masking stress corrosion. The investigation

will involve localised polishing of the surface followed by visual examination with the aid of a magnifying

glass and dye penetrating test. Cross-section of different pitting types:


Light abrasions or scratches to 120 grit polish equivalent or finer.

Only with zero pitting

NOTES:

• When the tank is received by the depot for Off-hire, the depot must provide UNITAS with an Internal

Inspection Report (“IIR”), see Appendix F. The IIR, on instruction by UNITAS, should include a shell

thickness test of between 18-21 points.

• Gas tanks should be purged after repair, as specified by UNITAS.

NOTE: (Lined tanks)

• Lined tanks must be opened with extreme caution to avoid damage to the linings. Ladders for man

entry must be cushioned against manlid neckring and tank shell. Non-destructive test of lining


continuity should be performed in accordance with lining manufacturer’s specifications. If ensure

seek advice from Unitas. Do not carry out spark test without approval from Unitas.

3. HEATING and COOLING

3.1 Steam Tube and Cap


Leaks

Damaged screw fittings

Missing dust caps

Missing or broken chain or cable

Distortion to the tank shell (due to over pressure)

NOTE:

• In all cases of damage the steam tubes must be pressure tested.

• Defective steam traps should be removed, replacement is not required

• Steam tube dust caps may be made from aluminium casting or stainless steel

3.2 Thermometer


Not operating correctly

Broken face or dial

Missing or insecure

Improperly fitted

Acceptable condition:

Condensation which does not prevent legibility

3.3 Electric Heating


Non-operational

Damage or deterioration that may allow moisture ingress to control boxes or elements

Insecure components, cables or terminals

Corroded terminals or components

Improper repairs

Earth leakage less than 1 megohm

Missing parts

NOTE:

• All parts must be well-maintained and fully operational. An electric function test is required at off-hire

and on-hire for every electric heated tank.

3.4 Refrigeration Machinery (Reefer tanks)


Non-operational

Damage or deterioration that may allow moisture ingress to control boxes or elements

Insecure components, cables or terminals

Corroded terminals or components

Improper repairs

Missing parts


Unoriginal parts (not from original manufacturer)

NOTES:

• All parts must be well-maintained and fully operational. A Pre-trip Inspection (“PTI”) is required by the

depot at off-hire and on-hire for every reefer tank. The following criteria must be observed:

o Unit mounting bolts must be present and tight

o Condenser fins and grille must be clean and unclogged

o Electrical compartments must be clean, corrosion-free and have effective door seals

o All decals, wiring diagrams and instruction plates must be present and legible

o Electrical connectors, air change vents and gas ports must be free of corrosion and be capped

as required

o There must not be excessive corrosion on lower steel parts which are at risk of contact with

sea water, such as the compressor and received tank mounting brackets

o The main power cord must be I good condition and free from cuts and corrosion

o Use a primary (mains) power supply in preference to a generator set for a PTI machinery

inspection

• When depot surveyor performs the visual check, ensure that each of the following machinery sections

are examined carefully:

o Main frame

o Compressor section

o Temperature record and/or controller compartment

o Condenser section

o Electrical compartment

o TX (thermostatic expansion) valve compartment

o Evaporator section

o Diesel drive

o Main power cable compartments

o Electrical cables, wiring and refrigerant piping

o Interior panels, plenums and screens


4. INSULATION AND CLADDING

4.1 Insulation


Missing insulation material

Saturation by water or cargo

Improper repairs

Deterioration by heat (burnt or baked)

Improper insulation material

4.2 Cladding


Cuts, holes, cracks or splits penetrating the cladding thickness and allowing moisture ingress

Gaps in cladding and patch joints allowing moisture ingress

Deterioration by heat (burnt or baked)

Insecure cladding or retaining straps

Surface damage or staining of cladding due to cargo contamination

Heavy corrosion

Improper repairs

Distorted beyond the limits of the ISO corner fittings

Dents, scratches, cracks greater than 15mm


Distortion not affecting security nor allowing moisture ingress except as stated above

Minor abrasion

Full belly GRP patch on existing aluminium cladding

NOTES:

• In all cases of damage to the cladding the tank shell, heating tubes and electrical components must

also be checked.

• The following criteria will also apply when assessing the type and extent of repair required. Use self-

colour polyester in-fill or overlay riveted patches [minimum 2mm (0.08inch) G.R.P. for G.R.P. cladding

– minimum 0.9mm(18swg) Alum Alloy for Alum alloy cladding in the same colour]. Minimum patch

size 150x150 mm (6inchx6inch)

• Extend patched to the retainers strap (stainless steel (“SS”) where the patch is within 30mm of the SS

strap. Care must be taken to ensure that drills or rivets do not damage the shell, steam tubes beneath

the cladding.


5. FRAME

Frames should be carefully examined for corrosion and paint degradation and where this is showing loss

of materials and paintwork estimates should be prepared to clean, de-rust and repaint frames using

approved paint systems and paint shade (RAL5002).

5.1 Corner Posts


Cuts, holes or gouges

Cracks or splits in welds or parent metal

Improper repairs

Dents or distortions of a formed or folded edge or face greater than 15mm (0.6inch) in depth irrespective

of length of deformation

Dents greater than 10mm (0.4inch) and less than 15mm (0.6inch) in depth in excess of two per post.

Dents greater than 10mm (0.4inch) extending over a length greater than 300mm (12inch)

Twisted bent or overplated beyond the requirement of ISO

Corrosion affecting the structural strength of the member.


Dents or distortions not exceeding 15mm (0.6inch) in depth except as qualified above

5.2 Top and Bottom Side and End Rails

NOT Acceptable condition:

Cuts, holes , gouges or splits

Cracks in welds or parent metal

Improper repairs

Dents or distortions greater than 25 mm (1 inch)

Out of straight greater than 25mm (1 inch) per 2m (79inch) length

Top and Bottom end rails bent more than 30mm over the full length of rail measured midway

Side rails bent more than 50mm over the full length of the rail measured midway

Distortion reducing clearance preventing operation of discharge valve

Twisted or bent outward beyond the limits of the ISO corner fittings

Severe corrosion

Loose or missing fasteners


Dents not exceeding 25mm (1 inch)

Dents in the bottom face of bottom rails which do not affect any formed edge

5.3 Ancillary Bracing


Cuts, holes, gouges or splits


Improper repairs

Dents or distortions greater than 25mm (1 inch) Twisted or bent outward beyond the limits of the ISO

corner fittings

Severe corrosion

Mislocation compared to original design



Dents and distortions less than 25mm (1 inch)

5.4 Tank Bearer Supports


Cuts, holes, gouges or splits


Improper repairs

Dents or distortion of a formed edge greater than 13mm ( 0.5 inch)

Dents or distortions of the face greater than 20mm (0.75 inch0

Severe corrosion

Twisted or bent outwards beyond the limits of the ISO corner fittings

Acceptable:

Dents not exceeding 13-20mm in depth as qualified above.

NOTE:

• In all cases of damage to the to the tank bearer support, the tank shell must also be inspected for

damage. In all cases of corrosion to the tank bearer supports, the section of the bearer attached to

the shell below the insulation must be checked for structural integrity. This will require local removal

of insulation.

5.5 Stacking Supports

NOT acceptable Condition:

Holed

Cracked

Outside the limits of the ISO corner fittings

Loose


6. PAINTWORK


Paint removed by spillage of cargo

Paint removed by improper handling

Corrosion or paint abrasion equal to, or more severe than Euro Standard Re4


Very superficial corrosion

Light discoloration

Light scuffs and scratches

NOTES:

• Paint damage and resulting corrosion must be repaired as part of routine maintenance

• Repaired area should be prepared for painting by cleaning to bright metal. An approved primer and

paint system must be used with the colour RAL 5002.


7. WALKWAY AND LADDER ASSEMBLY

7.1 Walkway


Any type of damage affecting safety

Insecure loose fasteners, missing parts

Improper welds and cuts affecting safety

Dents or distortions greater than 25mm (1inch)

Carbon steel bolts/nuts/washers

Twisted or bent upwards beyond the limits of the ISO corner-fitting

Unintentional differences in height between sections affecting safety

Elements of different origin of material (aluminium/galvanised steel) or different shapes


Dents or distortions not exceeding 25mm and not affecting safety

Cuts not affecting safety

7.2 Ladder

Ladder should be clean, secure and safe to use


Insecure

Cuts, holes, or splits, sharp edges or dents affecting safety

Dents and Distortions greater than 50mm( 2 inch ) measured over more than 1m length.

Dents and distortions greater than 25mm on ladder rungs

Dents greater than 25mm (1 inch)

Twisted or bent outwards beyond the limits of the ISO corner fittings

Missing fasteners or electrolytic barriers


Distortions smaller than 50mm (2 inch) measured over not less than 1m length and not affecting safety

Cuts not affecting safety


8. MANWAY ASSEMBLY

8.1 Manlid and Swing Bolt Assemblies


Leaks

Missing, insecure, seized or non-operational parts

Dents or distortion greater than 6mm (0.25inch) or affecting proper sealing of the manlid.

Cracks

Missing Customs sealing ring.

Pitting, corrosion or contamination.

Improper repairs.


Non-standard hand nuts which are similar design and similar material e.g. bronze or stainless steel

8.2 Manlid Seal


Cuts, cracks or distortion affecting sealing

Contamination

Square butt joint

Missing or insecure


Minor surface degradation which does not contain contamination and does not affect sealing

NOTE:

• The following criteria will apply when assessing the type and extent of repair required : Seals fitted

must be to UNITAS’ specification. Solid seals may be cleaned.

8.3 Dipstick and Calibration Chart


Distortion or damage to the dipstick assembly preventing operation

Non stainless steel

Contamination or corrosion

Illegible or insecure

NOTE:

• Dipsticks may or may not be standard. If there is doubt refer to UNITAS.


9. SAFETY RELIEF VALVES

9.1 Pressure Only or Pressure Vacuum Relief Valves



Missing parts

Distortion or damaged or worn threads affecting correct operation or security

Leaks or incorrect pressure setting

Missing or defective Customs sealing ring

Improper repairs, seals or gaskets.


Missing dust plug

PTFE or CF gaskets

9.2 Flame Arrestor Gauze (Where Fitted)

NOT acceptable Condition:

Missing if originally fitted

Damage affecting operation

Contamination

NOTE:

• Flame arrestors are not necessary on non-hazardous tanks or on Pressure Only Valves

9.3 Bursting Discs (Where Fitted)


Leaks or incorrect pressure rating


Broken disc

Improper parts

Damaged pressure gauge affecting correct operation

Missing tell tale pressure gauge

NOTE:

• Bursting discs may or may not be fitted as standard. Refer to UNITAS if in doubt. Many tanks have

bursting-disc flange assemblies fitted in series with the relief valve for the fitting of bursting discs if

required.


10. TOP VALVES

10.1 Airline and Airline Valves


Leaks


Damage or distortion of valve or screwed fittings affecting correct operation

Non-stainless steel (300 series)

Defective pressure gauge where fitted

Missing outlet cap or seal or retaining wire

Improper repairs seals or gaskets

Missing or non-operational Customs sealing ring


SWR or PTFE airline cap seals

Caps made from SS

10.2 Top Outlet


Leaks


Damage or corrosion affecting correct operation or sealing

Missing or defective parts


Non-stainless steel (300 series)

Non-standard parts (refer to UNITAS)

Missing or defective Customs sealing ring

10.3 Syphon Tube (Where Fitted)



Non-stainless steel Damage or distortion affecting correct operation or sealing

Gap between end tub and bottom of tank greater than 25mm


11. BOTTOM VALVES

11.1 Foot Valve


Leaks




Non-stainless steel


11.2 Bottom Outlet Valve


Leaks



Improper repairs, seals or gaskets

Non-stainless steel


NOTE:

• Foot valve to tank flange gaskets must be PTFE envelope CF

11.3 Outlet Blank


Leaks


Non-stainless steel

Damage or corrosion affecting operation

Missing Customs sealing ring

NOTE:

• Where renewal is necessary, bolts should be stainless steel

• Replacement gaskets should be PTFE envelope CF or solid PTFE

11.4 Screwed Outlet Cap


Leaks


Missing Parts

Non-metallic, or a material which is not corrosion resistant

Damaged or improper screw threads

Broken or missing retaining wire or chain

Damage affecting operation


Acceptable condition:

SWR seals

NOTE:

• Replacement caps must be secured by a chain

11.5 Remote Emergency Closure


Damage rendering remote closure inoperable

Seized

Insecure


12. APPENDAGES

12.1 Data Plates and Decals


Insecure

Incorrect Owner & Address information (CSC plate)

Missing or illegible plates (CSC, Customs, Data, Owner)

Missing, illegible, obscured or partly missing decals and logos

Twisted or bent beyond the limits of ISO (Data Plates)

Missing Approved Cargo List (gas tanks only)


Scuffs (Data Plates only)

Dents to Data Plates except as stated above

NOTES:

• All Data Plates and decals required by applicable regulations must be in place. Refer to UNITAS for

details of the data plates and decals to be fitted

• UNITAS decals should be fitted after depot repair as per the UNITAS Decals Specification, see

Appendix H.

12.2 Document Holder


Missing or defective

Insecure

No drain hole

Water filled

Acceptable condition :

Non-standard type

12.3 Compartments and Compartment Lids


Non-operational

Twisted or bent beyond the limits of the ISO corner fittings

Splits or tears

Cargo residues, dirt, sundry waste

Blocked drain tubes

Damaged

Insecure doors/lids where fasteners do not properly secure the lid for transport

Missing customs sealing ring and door fasteners

Improper repairs affecting structural integrity

Severe corrosion

12.4 Earthing (Ground) Lug


Damaged


Missing

Painted

13 TESTING

13.1 Air Leak Test

• The tank must be pressurised with air to 1 bar (15 psi) and all fittings and flanges checked with

liquid soap at Offhire

• Leak checks to 1 bar (15 psi) are required to all tanks as part of the completed depot repair

inspection

• Where tanks are stored in depot for periods more than six months from the time of the

completed repair inspection, the air leak test should be repeat prior to Onhire

13.2 Hydraulic Test

• Mandatory retesting with water is required after all welded repairs to the shell of hazardous tanks

(see applicable regulations)

13.3 Statutory Test

• Hazardous cargoes may only be transported in tanks which have a valid 2.5 or 5 year Periodic Test

Certificate issues by a Classification Society. Consult UNITAS for which Classification Society to

use.

• Data plate should be inspected to check when the last Periodic Test was conducted


APPENDIX A: Cleanliness Certificate


APPENDIX B: Corner Post Repairs

NOT Acceptable Repairs:

1 2 3 4

1a. insert through 3 formed edges

1b. less than 300mm from casting

2. less than 150mm between inserts

3. overlapping inserts

4. more than two inserts per post


APPENDIX B: Corner Post Repairs

Acceptable Repairs:

1 2 3 4

1a. Minimum distance between inserts is 150 mm.

1b. Minimum size insert is 150 mm.

2. Minimum insert at post ends is 300 mm.

3. A full-length insert is allowed.

4. Two inserts may have a common weld.


APPENDIX C: Cladding

Section through cladding patch:


APPENDIX D: Manlid

Section through manlid:


APPENDIX E: Safety Relief Valve

Section through relief valve:


APPENDIX F: Internal Inspection Report


APPENDIX G: ISO Dimensions & Tolerances


APPENDIX H: UNITAS Decals Specification

unitas repair manual repair manual issue 4 jun 2014(0).pdfthe purpose of the unitas repair manual...

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